Laminate structures and flexible packaging materials incorporating same

ABSTRACT

Embodiments of the present disclosure are directed to laminates comprising a uniaxially oriented first multilayer film comprising ethylene-based polymer, wherein the uniaxially oriented first multilayer film has a ratio of percent elongation at break in the cross direction to percent elongation at break in the machine direction of at least 2 to 1; a biaxially oriented second multilayer film adhered to the uniaxially oriented first multilayer film and comprising an ethylene-based polymer, wherein the biaxially oriented second multilayer film has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction of at least 2 to 1; and a third film adhered to the biaxially oriented second multilayer film such that the biaxially oriented second multilayer film is disposed between the uniaxially oriented first multilayer film and the third film, wherein the third film comprises an ethylene-based polymer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage Entry under 35 U.S.C. § 371 of International Patent Application No. PCT/CN2018/124682, filed Dec. 28, 2018, the entire disclosures of which are incorporated by reference herein.

TECHNICAL FIELD

Embodiments described herein relate generally to laminate structures, and more particularly relate to laminate structures for flexible packaging materials.

BACKGROUND

Large stand up pouches (SUP) for liquid or granular packaging of 2 to 5 Liter (L) content are typically made of triplex laminates, and have a structure comprising Biaxially Oriented Polyethylene Terephthalate (BOPET)/Biaxially Oriented Polyamide (BOPA)/Polyethylene Sealant. One critical performance requirement is the drop test of the pouch, and a minimum drop height is specified under which the pouch should not break if dropped. Laminate structures mentioned above have been used in the market, however due to changing regulations and the increasing demand to use recyclable packaging, there is a desire to provide large SUP made of monomaterials, preferably polyethylene. While these polyethylene mono-material laminates are desirable from a recyclability standpoint, achieving the desired mechanical properties (e.g., heat seal strength) has been challenging.

Accordingly, there is a need for improved laminates and processes for making these laminates for use in flexible packaging embodiments, wherein the laminates have the dual benefits of recyclability and mechanical strength.

SUMMARY

Embodiments of the present disclosure meet those needs by providing laminates having recyclability and mechanical strength. The present laminates combine the benefits of biaxially oriented polyethylene (B OPE) films with that of uniaxially (machine direction) oriented polyethylene films (MDO-PE) films and a third film (also called sealant film). The mechanical and thermal properties of the MDO/BOPE/sealant triplex laminate beneficially enhances each other to provide a structure that provides the required mechanical strength and the required recyclability

Specifically, the high machine direction (MD) stiffness and tensile strength of the MDO film and the low stiffness and tensile strength in the cross direction (CD) is compensated by the low stiffness and tensile strength of BOPE films in the MD direction and high stiffness and tensile strength in the CD direction. The resulting laminated film has a balanced MD and CD stiffness and tensile strength, and a good tensile elongation, to provide strong laminates to resist packaging abuse, specifically packaging abuse in drop tests.

According to at least one laminate embodiment, the laminate comprises a uniaxially oriented first multilayer film comprising ethylene-based polymer having a density from 0.930 to 0.970 g/cm³ and a melt index (I₂) from 0.1 to 10 g/10 minutes, wherein the uniaxially oriented first multilayer film is oriented in the machine direction at a draw ratio greater than 3:1 and less than 8:1, and wherein the uniaxially oriented first multilayer film has a ratio of percent elongation at break in the cross direction to percent elongation at break in the machine direction of at least 2 to 1. The laminate also comprises a biaxially oriented second multilayer film adhered to the uniaxially oriented first multilayer film and comprising an ethylene-based polymer having a density from 0.900 to 0.962 g/cm³, wherein the biaxially oriented second multilayer film has a cross directional draw ratio larger than its machine direction draw ratio, and wherein the biaxially oriented second multilayer film has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction of at least 2 to 1. Moreover, the laminate comprises a third film adhered to the biaxially oriented second multilayer film such that the biaxially oriented second multilayer film is disposed between the uniaxially oriented first multilayer film and the third film, wherein the third film comprising an ethylene-based polymer having a density from 0.865 g/cm³ to 0.935 g/cm³ and a melt index (I₂) from 0.5 to 5 g/10 minutes.

These and other embodiments are described in more detail in the following detailed description.

DETAILED DESCRIPTION

Specific embodiments of the present application will now be described. The disclosure may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth in this disclosure. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the subject matter to those skilled in the art.

Definitions

The term “polymer” refers to a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer thus embraces the term “homopolymer,” usually employed to refer to polymers prepared from only one type of monomer as well as “copolymer” which refers to polymers prepared from two or more different monomers. The term “interpolymer,” as used herein, refers to a polymer prepared by the polymerization of at least two different types of monomers. The generic term interpolymer thus includes copolymers, and polymers prepared from more than two different types of monomers, such as terpolymers.

“Polyethylene” or “ethylene-based polymer” shall mean polymers comprising greater than 50% by mole of units which have been derived from ethylene monomer. This includes polyethylene homopolymers or copolymers (meaning units derived from two or more comonomers). Common forms of polyethylene known in the art include Low Density Polyethylene (LDPE); Linear Low Density Polyethylene (LLDPE); Ultra Low Density Polyethylene (ULDPE); Very Low Density Polyethylene (VLDPE); single-site catalyzed Linear Low Density Polyethylene, including both linear and substantially linear low density resins (m-LLDPE); Medium Density Polyethylene (MDPE); and High Density Polyethylene (HDPE).

The term “propylene-based polymer,” as used herein, refers to a polymer that comprises, in polymerized form, refers to polymers comprising greater than 50% by mole of units which have been derived from propylene monomer. This includes propylene homopolymer, random copolymer polypropylene, impact copolymer polypropylene, propylene/α-olefin copolymer, and propylene/α-olefin copolymer.

The term “LDPE” may also be referred to as “high pressure ethylene polymer” or “highly branched polyethylene” and is defined to mean that the polymer is partly or entirely homopolymerized or copolymerized in autoclave or tubular reactors at pressures above 14,500 psi (100 MPa) with the use of free-radical initiators, such as peroxides (see for example U.S. Pat. No. 4,599,392, which is hereby incorporated by reference). LDPE resins typically have a density in the range of 0.916 to 0.935 g/cc.

The term “LLDPE”, includes both resin made using the traditional Ziegler-Natta catalyst systems as well as single-site catalysts, including, but not limited to, bis-metallocene catalysts (sometimes referred to as “m-LLDPE”) and constrained geometry catalysts, and includes linear, substantially linear or heterogeneous polyethylene copolymers or homopolymers. LLDPEs contain less long chain branching than LDPEs and include the substantially linear ethylene polymers which are further defined in U.S. Pat. Nos. 5,272,236, 5,278,272, 5,582,923 and 5,733,155; the homogeneously branched linear ethylene polymer compositions such as those in U.S. Pat. No. 3,645,992; the heterogeneously branched ethylene polymers such as those prepared according to the process disclosed in U.S. Pat. No. 4,076,698; and/or blends thereof (such as those disclosed in U.S. Pat. No. 3,914,342 or 5,854,045). The LLDPEs can be made via gas-phase, solution-phase or slurry polymerization or any combination thereof, using any type of reactor or reactor configuration known in the art.

The term “MDPE” refers to polyethylenes having densities from 0.926 to 0.935 g/cm3. “MDPE” is typically made using chromium or Ziegler-Natta catalysts or using single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts, and typically have a molecular weight distribution (“MWD”) greater than 2.5.

The term “HDPE” refers to polyethylenes having densities greater than about 0.935 g/cm3, which are generally prepared with Ziegler-Natta catalysts, chrome catalysts or single-site catalysts including, but not limited to, bis-metallocene catalysts and constrained geometry catalysts.

As used herein, the term, “monomaterial” means that the laminate structures are composed substantially of polyethylene, wherein “substantially” means at least 95 wt. % polyethylene, or at least 99 wt. % polyethylene, or at least 99.5 wt. % polyethylene, or at least 99.9 wt. % based on the overall weight of the laminate structure.

“Multilayer structure” means any structure having more than one layer. For example, the multilayer structure may have two, three, four, five or more layers. A multilayer structure may be described as having the layers designated with letters. For example, a three layer structure having a core layer B, and two external layers A and C may be designated as A/B/C.

The terms “flexible packaging” or “flexible packaging material” encompass various non-rigid containers familiar to the skilled person. These may include pouches, stand-up pouches, pillow pouches, or bulk bags bulk bags, pre-made packages or the like. Some typical end use applications for flexible packages are for snack, dry food, liquid, or cheese packages. Other end use applications include, but are not limited to, pet foods, snacks, chips, frozen foods, meats, hot dogs, and numerous other applications.

The terms “comprising,” “including,” “having,” and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term, “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step or procedure, excepting those that are not essential to operability. The term “consisting of” excludes any component, step or procedure not specifically delineated or listed.

Reference will now be made in detail to laminate structure embodiments of the present disclosure, specifically laminate structures used in flexible packaging materials.

Embodiments are directed to laminates comprising a uniaxially oriented first multilayer film comprising ethylene-based polymer having a density from 0.900 to 0.962 g/cm³ and a melt index (I₂) from 0.1 to 10 g/10 minutes. The uniaxially oriented first multilayer film, which may also be referred to herein as an MDO film or an MDO-PE film, is oriented in the machine direction at a draw ratio greater than 1:1 and less than 8:1. Moreover, the uniaxially oriented first multilayer film has a ratio of percent elongation at break in the cross direction to percent elongation at break in the machine direction of at least 2 to 1.

Additionally, the laminate comprises a biaxially oriented second multilayer film adhered to the uniaxially oriented first multilayer film. The laminate comprises an ethylene-based polymer having a density from 0.900 to 0.962 g/cm³. The biaxially oriented second multilayer film has a cross directional draw ratio larger than its machine direction draw ratio, and the biaxially oriented second multilayer film has a wherein the biaxially oriented second multilayer film has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction of at least 2 to 1.

Furthermore, the laminate comprises a third film adhered to the biaxially oriented second multilayer film such that the biaxially oriented second multilayer film is disposed between the uniaxially oriented first multilayer film and the third film. The third film, which may also described as a blown film polyethylene sealant film, comprises an ethylene-based polymer having a density from 0.865 g/cc to 0.935 g/cc and a melt index (I₂) from 0.5 to 5 g/10 minutes.

Uniaxially Oriented First Multilayer Film

In one or more embodiments, the uniaxially oriented first multilayer film may include HDPE in at least one layer in order to provide heat resistance for the laminate during heat seal. In one or more embodiments, the uniaxially oriented first multilayer film comprises at least 10% by weight HDPE, or at least 15% by weight HDPE, or at least 20% by weight HDPE. The uniaxially oriented first multilayer film may include 95% by weight ethylene-based polymer, or 99% by weight ethylene-based polymer, or 99.9% by weight ethylene-based polymer, or 100% by weight ethylene-based polymer. The high density polyethylene of the uniaxially oriented first multilayer film may have a density of at least 0.950 g/cc, or at least 0.950 g/cc, or at least 0.960 g/cc. In other embodiments, the high density polyethylene may have a density from 0.950 to 0.975 g/cc, or from 0.955 to 0.970 g/cc. Moreover, the high density polyethylene may have a melt index from 0.5 to 2 g/10 mins, or from 0.6 to 1 g/10 mins. Commercial Examples may include ELITE™ 5960G from The Dow Chemical Company, Midland, Mich.

Various thicknesses are contemplated for the uniaxially oriented first multilayer film. In one embodiment, the uniaxially oriented first multilayer film has a thickness from 15 to 30 win.

In another embodiment, the uniaxially oriented first multilayer film may comprise at least one outer layer having a high density polyethylene comprising a density of at least 0.950 g/cc, and a melt index (I₂) from 0.3 to 5 g/10 mins, at least one inner layer comprising an ethylene-based polymer having a density less than 0.920 g/cc and a melt index from 0.5 to 5 g/10 mins, and at least one intermediate layer disposed between the at least one inner layer and the at least one outer layer, the intermediate layer comprising an ethylene based polymer having a density greater than 0.930 g/cc.

The high density polyethylene in the outer layer may include the density ranges and melt index values provided above. The outer layer may have a thickness of 2 to 10 μm, or from 2 to 4 μm.

As stated above, at least one inner layer comprising an ethylene-based polymer having a density less than 0.920 g/cc and a melt index from 0.5 to 5 g/10 mins. In one or more embodiments, the inner layer may include a polyolefin plastomer having a density less than 0.900 g/cc, or less than 0.900 g/cc, or less than 0.890 g/cc, or less than 0.880 g/cc, or less than 0.875 g/cc. In further embodiments, the polyolefin plastomer of the inner layer has a density from 0.860 to 0.900 g/cc, or from 0.860 to 0.885 g/cc, or from 0.865 to 0.875 g/cc. Moreover, the polyolefin plastomer of the inner layer has a melt index from 0.5 to 3 g/10 mins, or from 0.6 to 1.5 g/10 mins, or from 0.8 to 1.2 g/10 mins. Commercial Examples of the polyolefin plastomer may include AFFINITY™ 8100, AFFINITY™ 8200, AFFINITY™ 1880, and AFFINITY™ 1140, all of which are available from The Dow Chemical Company, Midland, Mich.

In some embodiments, for example, non-blocked asymmetric film embodiments, it is contemplated that the inner layer comprises an additional ethylene-based polymer blended with the polyolefin plastomer. Various embodiments are contemplated for the ethylene based polymer. In one or more embodiments, the inner layer comprises a density greater than 0.910 g/cc and a melt index (I₂) from 0.5 to 5 g/10 mins. Suitable commercial examples may include ELITE™ or INNATE™ polymers available from The Dow Chemical Company, Midland, Mich. The inner layer may have a thickness of 2 to 10 μm, or from 2 to 5 μm.

In the intermediate layer of the uniaxially oriented first multilayer film, the ethylene based polymer may have a density greater than 0.930 g/cc, or greater than 0.935 g/cc. In other embodiments, the ethylene-based polymer may have a density from 0.920 to 0.950 g/cc, or from 0.925 to 0.945 g/cc, or from 0.935 to 0.945 g/cc. Moreover, the ethylene-based polymer of the intermediate layer may have a melt index from 0.5 to 2 g/10 mins, or from 0.6 to 1 g/10 mins. Commercial Examples may include ELITE™ 5940ST from The Dow Chemical Company, Midland, Mich. The intermediate layer may have a thickness of 8 to 30 μm.

In yet another embodiment, the uniaxially oriented first multilayer film may include a propylene-based polymer. The propylene-based polymer may be used alone or in combination with the embodiments described herein. The propylene-based polymer may have a density of 0.850 g/cc to 0.900 g/cc, or 0.855 to 0.895. The propylene-based polymer may have a melt flow rate (MFR) of 1 to 25, or 1 to 10 g/10 mins. Various commercial embodiments are contemplated as suitable. These may include Vistamaxx™ 3000, Vistamaxx™ 3020FL, Vistamaxx™ 3588FL and Vistamaxx™ 6102/6102FL, which are produced by ExxonMobil. Additionally, VERSIFY™ 2000 and VERSIFY™ 2300 from The Dow Chemical Company, Midland, Mich. may also be utilized.

Various processing parameters are considered suitable for stretching in the machine direction. For example, the uniaxially oriented first multilayer film may be oriented in the machine direction at a draw ratio greater than 3:1 and less than 8:1, or at a draw ratio from 4:1 to 8:1.

As stated above, the uniaxially oriented first multilayer film has a ratio of percent elongation at break in the cross direction to percent elongation at break in the machine direction of at least 2 to 1. In further embodiments, the ratio of the percent elongation at break in the cross direction to percent elongation at break in the machine direction is at least 3 to 1, or at least 5 to 1, or at least 8 to 1 for the uniaxially oriented first multilayer film. Said another way, the uniaxially oriented first multilayer film has percent elongation at break in the cross direction greater by at least 100% than the percent elongation at break in the machine direction, or greater by at least 200%, or greater by at least 300%.

Biaxially Oriented Second Multilayer Film

It is contemplated that the biaxially oriented second multilayer film may be a monolayer film or a multilayer film. For example, the biaxially oriented second multilayer film can further comprise other layers typically included in multilayer films depending on the application including, for example, sealant layers, barrier layers, tie layers, other polyethylene layers, etc. In one or more embodiments, the biaxially oriented second multilayer film may have a thickness from 15 to 100 μm, or from 15 to 40 μm. The biaxially oriented second multilayer film may include 95% by weight ethylene-based polymer, or 99% by weight ethylene-based polymer, or 99.9% by weight ethylene-based polymer, or 100% by weight ethylene-based polymer.

The ethylene-based polymer of the biaxially oriented second multilayer film may have a density from 0.915 to 0.940 g/cc, or from 0.920 to 0.935 g/cc, or from 0.920 to 0.930 g/cc. The biaxially oriented second multilayer film may have a melt index from 0.5 to 2 g/10 mins, or from 0.6 to 1 g/10 mins.

The biaxially oriented second multilayer film may comprise a linear low density polyethylene (LLDPE). Suitable LLDPE's include Ziegler-Natta catalyzed linear low density polyethylene, single site catalyzed (including metallocene) linear low density polyethylene (mLLDPE), and medium density polyethylene (MDPE) so long as the MDPE has a density no greater than 0.940 g/cm³ as well as combinations of two or more of the foregoing. The LLDPE may have a density and melt index (I₂) as defined by the ranges above. The biaxially oriented second multilayer film can comprise greater than 50 weight percent LLDPE in some embodiments, greater than 60 weight percent in other embodiments, and greater than 70 weight percent in other embodiments.

In some embodiments, the biaxially oriented second multilayer film can further comprise one or more additional polymers including, for example, a high density polyethylene, a low density polyethylene, an ultra-low density polyethylene, a polyethylene plastomer, a polyethylene elastomer, an ethylene vinyl acetate, or a combination thereof. In such embodiments, the one or more additional polymers can be present in an amount less than 50 weight percent.

The biaxially oriented polyethylene film can further comprise one or more additives as known to those of skill in the art such as, for example, antioxidants, phosphites, cling additives, anti-static agents, pigments, colorants, fillers, or combinations thereof.

In one or more embodiments, the biaxially oriented second multilayer film is biaxially oriented using a tenter frame sequential biaxial orientation process. Such techniques are generally known to those of skill in the art. In other embodiments, the polyethylene film can be biaxially oriented using other techniques known to those of skill in the art based on the teachings herein, such as double bubble orientation processes. In general, with a tenter frame sequential biaxial orientation process, the tenter frame is incorporated as part of a multilayer co-extrusion line. After extruding from a flat die, the film is cooled down on a chill roll, and is immersed into a water bath filled with room temperature water. The cast film is then passed onto a series of rollers with different revolving speeds to achieve stretching in the machine direction. There are several pairs of rollers in the MD stretching segment of the fabrication line, and are all oil heated. The paired rollers work sequentially as pre-heated rollers, stretching rollers, and rollers for relaxing and annealing. The temperature of each pair of rollers is separately controlled. After stretching in the machine direction, the film web is passed into a tenter frame hot air oven with heating zones to carry out stretching in the cross direction. The first several zones are for pre-heating, followed by zones for stretching, and then the last zones for annealing.

In some embodiments, the biaxially oriented second multilayer film is oriented in the machine direction at a draw ratio from 2:1 to 6:1 and in the cross direction at a draw ratio from 2:1 to 9:1. The biaxially oriented second multilayer film, in some embodiments, is oriented in the machine direction at a draw ratio from 3:1 to 5:1 and in the cross direction at a draw ratio from 3:1 to 8:1.

The biaxially oriented second multilayer film has a cross directional draw ratio larger than its machine direction draw ratio, and the biaxially oriented second multilayer film has a wherein the biaxially oriented second multilayer film has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction of at least 2 to 1. In further embodiments, the ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction is at least 3 to 1, or at least 4 to 1 for the biaxially oriented second multilayer film. Said another way, wherein the biaxially oriented second multilayer film has percent elongation at break in the machine direction greater by at least 100% than percent elongation at break in the cross direction, or greater by at least 200%, or greater by at least 300%.

Third Film

Like the biaxially oriented second multilayer film, the third film, which may also be called a sealant film or a blown sealant film, may be a multilayer film or a monolayer film. Unlike the uniaxially oriented and biaxially oriented films, it is contemplated that the sealant film is not oriented in some embodiments. In further embodiments, the third film may have a Heat Seal Initiation temperature below 110° C., or below 100° C. The third film may have a layer thickness from 40 to 100 μm, or from 60 to 80 μm.

The multilayer sealant film may include a plurality of layers comprising ethylene based polymer. In one embodiment, the third film comprises a linear low density polyethylene (LLDPE) having a density from 0.900 to 0.930 g/cc and a melt index (I₂) from 0.5 to 5.0 g/10 mins. In further embodiments, the LLDPE may have a density from 0.905 to 0.925 g/cc, or from 0.910 to 0.925 g/cc. Moreover, the LLDPE may have a melt index (I₂) from 0.5 to 2.5 g/10 mins, or from 0.75 to 1.5 g/10 mins, or from 0.9 to 1.2 g/10 mins. Additionally, the third film may comprise a low density polyethylene (LDPE) having a density from 0.915 to 0.935 g/cc and a melt index (I₂) from 0.3 to 5.0 g/10 mins. In further embodiments, the LDPE may have a density from 0.910 to 0.935 g/cc, or from 0.920 to 0.930 g/cc. Moreover, the LDPE may have a melt index (I₂) from 0.5 to 2.5 g/10 mins, or from 0.6 to 1.0 g/10 mins.

It is contemplated that one or more layers of the third film may comprise a blend of LLDPE and LDPE. For example, the LLDPE/LDPE blend may include at least 50% by weight, at least 60%, at least 70% by weight, or at least 80% by weight of LLDPE. Conversely, the LLDPE/LDPE blend may include from 1 up to 50% by weight, or up to 40% by weight LDPE, or up to 30% by weight, or up to 20% by weight LDPE.

In some embodiments, a first layer of the sealant film comprises at least 30 percent by weight of a polyolefin plastomer, a polyolefin elastomer, an ultra-low density polyethylene, an ethylene acetate copolymer, an ethylene acrylic acid copolymer, or an ethylene acrylate copolymer.

When the sealant film comprises a polyolefin plastomer, the polyolefin plastomer can be a polyethylene plastomer or a polypropylene plastomer. Polyolefin plastomers include resins made using single-site catalysts such as metallocenes and constrained geometry catalysts. The polyolefin plastomer has a density of 0.885 to 0.915 g/cc. All individual values and subranges from 0.885 g/cc to 0.915 g/cc are included herein and disclosed herein, for example, the density of the polyolefin plastomer can be from a lower limit of 0.895, 0.900, or 0.905 g/cc to an upper limit of 0.905, 0.910, or 0.915 g/cc. In some embodiments, the polyolefin plastomer has a density from 0.890 to 0.910 g/cc.

In some embodiments, the polyolefin plastomer has a melt index (I₂) of up to 20 g/10 minutes. All individual values and subranges up to 20 g/10 minutes are included herein and disclosed herein. For example, the polyolefin plastomer can have a melt index to an upper limit of 1.0, 2.0, 3.0, 4.0, 5.0, 6.0, 7.0, 8.0, 9.0, 10.0, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 g/10 minutes. In a particular aspect, the polyolefin plastomer has an I₂ with a lower limit of 0.5 g/10 minutes. Examples of polyolefin plastomers that can be used in the sealant film include those commercially available from The Dow Chemical Company under the name AFFINITY™ including, for example, AFFINITY™ PL 1881G and AFFINITY™ PF1140G.

Adhesive Layers

Various adhesive compositions are considered suitable for the adhesives used the laminate. These may include polyurethane, epoxy, acrylic, or the like. In one embodiment, the laminate may comprises adhesive layers comprising polyurethane adhesive. The polyurethane adhesive may be solventless, waterborne or solvent based. Furthermore, the polyurethane adhesive may be a two part formulation.

The weight or thickness of the adhesive layer can depend on a number of factors including, for example, the desired thickness of the multilayer structure, the type of adhesive use d, and other factors. In some embodiments, the adhesive layer is applied at up to 5.0 grams/m², or from 1.0 to 4.0 g/m², or from 2.0 to 3.0 g/m².

Laminate

Without being limited by theory, the combination of the three films provides an isotropic laminate. As used herein, “isotropic” means the laminate has a percent elongation at break in the cross direction within 30% of the percent elongation at break in the machine direction. Said another way, this means that the laminate yield similar tensile results in the MD direction or the cross direction. In further embodiments, the present laminates may have a percent elongation at break in the cross direction within 25%, or within 20% of the percent elongation at break in the machine direction. Moreover, the laminate may have a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction ranging from 1.3:1 to 1:1.3, or from 1.2:1 to 1:1.2, or from 1.1:1 to 1:1.1.

Article

As stated above, the laminate may be included in a flexible packaging material, such as a stand-up pouch.

Testing Methods

The test methods include the following:

Melt Index (I₂)

The Melt index (I₂) of the ethylene-based polymers was measured in accordance to ASTM D-1238 at 190° C. at 2.16 kg. The values are reported in g/10 min, which corresponds to grams eluted per 10 minutes.

Melt Flow Rate (MFR)

The Melt Flow Rate of the propylene-based polymers was measured according to ASTM D-1238 at 230° C. and 2.16 kg. The values are reported in g/10 min, which corresponds to grams eluted per 10 minutes.

Density

Samples for density measurement were prepared according to ASTM D4703 and reported in grams/cubic centimeter (g/cc or g/cm³). Measurements were made within one hour of sample pressing using ASTM D792, Method B.

Tensile Properties

Percent elongation, elongation at break, and force at break were determined in both the machine direction (MD) and cross direction (CD) in accordance with the ASTM D-882-method. The machine used was an Instron 5965 Tensile Tester and operated with a pulling speed of 500 mm/min. The sample width was 1 inch.

Heat Seal Testing

To determine heat seal strength and heat seal initiation temperature, the samples were sealed by a J&B Hot Tack 4000 Tester. The sample width was 1 inch, the seal time was 0.5 seconds, and the seal pressure was 0.275 N/mm². Then, the sealed samples were aged for 24 hours before heat seal strength was tested on an Instron 5965 Tensile Tester at a pulling speed of 500 mm/min.

EXAMPLES

The following examples illustrate features of the present disclosure but are not intended to limit the scope of the disclosure.

Commercial Polymers Used

The following listed polymers were used in the experimental laminates described below. All of the polymers are produced by The Dow Chemical Company, Midland, Mich. Additionally, the laminate examples utilized the following 2 commercially available adhesives available from The Dow Chemical Company, Midland, Mich. The first adhesive is MOR-FREE™ L75-300+MF L75-300+CR88-300 (hereinafter “MOR-FREE”), which is a two part solventless polyurethane adhesives. The second adhesive is ADCOTE™ 675A+675C (hereinafter “ADCOTE”), which is a solvent-based two-component polyurethane adhesive.

The polymer synthesis for LLDPE 1 is provided after Table 1.

TABLE 1 Polymer Density (g/cc) Melt Index (g/10 mins) ELITE ™ 5940ST 0.941 0.85 ELITE ™ 5960G 0.96 0.85 AFFINITY ™ EG 8100G 0.870 1.0 LLDPE 1 0.916 1.05 LDPE 310E 0.924 0.75

Synthesis of LLDPE 1

LLDPE 1 is an ethylene-hexene copolymer prepared via solution polymerization process in a single reactor in the presence of a catalyst system comprising a metal complex of a polyvalent aryloxyether having a melt index (I2) of 1.05 g/10 minutes, a density of 0.916 g/cm3, a CEF fraction from 70 to 90° C. of 90.3%, an I₁₀/I₂ of 7.3. Inventive composition 1 is prepared via solution polymerization in a single loop reactor system as described in U.S. Pat. No. 5,977,251 in the presence of a Zirconium based catalyst system (“Post-Metallocene Catalyst”) comprising [2,2′″-[1,3-propanediylbis(oxy-κO)]bis[3″,5,5″-tris(1,1-dimethylethyl)-5′-methyl[1,1′:3′,1″-terphenyl]-2′-olato-κO]]dimethyl-, (OC-6-33)-Zirconium, represented by the following formula:

The polymerization conditions for LLDPE 1 are reported in Tables 2 and 3. Referring to Table 3, TEA is triethylaluminum and PETROSOL D 100/120 is solvent which is commercially available from CEPSA (Compañía Española de Petroleos, S.A.U., Madrid, Spain).

TABLE 2 Units LLDPE 1 1. REACTOR FEEDS Reactor Solvent/Ethylene Feed g/g 4.04 Flow ratio Solvent Type Used PETROSOL D 100/120 Comonomer Type Used 1-Hexene Reactor Comonomer/Ethylene Feed g/g 0.263 Flow ratio Reactor Fresh Hydrogen/ethylene g/kg 0.058 Feed Flow ratio Reactor Control Temperature ° C. 160 Reactor Pressure (gauge) Bar 52 Reactor Ethylene Conversion % 86.9 Reactor Residence Time Min 6.5 Recycle Ratio 4.2

TABLE 3 LLDPE 1 2. CATALYST Reactor Co-Catalyst-1/Catalyst 2.0 Molar feed Ratio Reactor Co-Catalyst-1 Type bis(hydrogenated tallow alkyl)methyl, tetrakis(pentafluorophenyl)borate(1-) amine Reactor Co-Catalyst-2/Catalyst 42 Molar Ratio Reactor Co-Catalyst-2 Type TEA

Fabrication of BOPE Films

Referring to Table 4 below, BOPE Samples 1, 2 and 3 are commercial BOPE products from Decro, specifically DL25 for 25 μm BOPE Sample 1, DL30 for 30 μm BOPE Sample 2, and DL50 for 50 μm BOPE Sample 3. The DL25, DL30 and DL50 BOPE films include a polyethylene polymer with a density of 0.925 g/cc

As shown in Table 4, these BOPE Samples of various thicknesses were studied. The data illustrates that in MD direction of the film, the tensile curve is rather flat shows high elongation at break. The CD tensile direction was very stiff and had low elongation at break. This asymmetric difference in MD and CD tensile behavior is not beneficial for drop test resistance. In addition, the thermal resistance of this BOPE film was lower than desired, and shrinkage could occur when the film is heated above 130° C.

TABLE 4 Thick- Elongation at Stress at Elongation at Stress at BOPE ness Break MD Break MD Break CD Break CD Sample (μm) (%) (MPa) (%) (MPa) Sample 1 25 262 111.4 50 240.4 Sample 2 30 341 147.1 60 266.1 Sample 3 50 356 110.2 61 188.8

Fabrication of MDO Films

Referring to Table 5 below, an MDO film (MDO Sample 1) was prepared on a blown film MDO line at a draw ratio of 6.5. The die head had a 400 mm diameter with output of 448 kg/h, and a final winding speed of 226 m/min. The Blow Up Ratio (BUR) used was 2.6 (layflat before stretching was 1650 mm). The primary film thickness (before blocking) was 64 μm. The secondary film thickness (after stretching) was 25 μm. (600% stretching). The die temperature was 200° C., except for 210° C. in the last two zones. Extrusion temperatures were all set at 200° C.

TABLE 5 MDO Thickness Thickness Sample 1 Before After Layer Stretching Stretching Structure Composition (μm) (μm) A ELITE 5960G 18 3 B ELITE 5940ST 30 5 C AFFINITY 8100G 12 2 C AFFINITY 8100G 12 2 B ELITE 5940ST 30 5 A ELITE 5960G 18 3

The film tensile behavior of the MDO Sample 1 film is listed in the following Table 6. As shown, the MDO film had high elongation at break in the CD direction but was much stiffer in the MD direction as demonstrated by a much lower elongation at break. Thus, it compensated for the tensile properties of the BOPE film.

TABLE 6 Elongation Force at Stress at Elongation Force at Stress at MDO Thickness at Break Break MD Break MD at Break Break CD Break CD Sample (μm) MD (%) (N) (MPa) CD (%) (N) (MPa) Sample 1 20 18% 49.86 184.65 441% 4.80 17.76

Third Film (Sealant Film)

The above two films were then laminated to a sealant film web made of a coextruded PE film, which had the tensile properties shown in Table 7 below. As shown, the tensile properties of the 70 μm sealant film are isotropic as demonstrated by an essentially equivalent elongation at break in the MD and CD directions.

TABLE 7 Thick- Elongation at Stress at Elongation at Stress at BOPE ness Break MD Break MD Break CD Break CD Sample (μm) (%) (MPa) (%) (MPa) Sealant 70 645 40.7 654 36.6 Film

The 70 μm sealant film was produced on an Alpine Blown film line with a 200 mm die, and a BUR of 2.5. The film had a coextruded ABC three layer structure as follows: A=80% by weight LLDPE 1+20% by weight LDPE 310E; B=LLDPE 1+20% LDPE 310E; and C=80% by weight LLDPE 1+20% LDPE 310E.

Laminate Procedure

For the lamination process, a Nordmeccanica™ Labo Combi 400 laminator was used. For the Inventive Triplex Samples 1 and 2 in Table 8, the adhesive was applied onto one surface of the BOPE film using a typical doctor blade, after which the second film (MDO Sample 1 film) was pressed against the BOPE film at a nip region to produce a duplex laminate. An adhesive was then applied on the duplex laminate, specifically applied on the opposite surface of the BOPE film. At which point, the duplex laminates were pressed against the sealant film to produce the Inventive Triplex Laminates. The Comparative Triplex Laminates were produced in the same manner albeit with different film combinations and compositions than the specific film combinations of Inventive Triplex Samples 1 and 2.

Triplex Laminate Examples

TABLE 8 Elongation at Stress at Elongation at Stress at Triplex Laminate Break MD Break MD Break CD Break CD Sample Structure (%) (MPa) (%) (MPa) Inventive MDO Sample 1/ 47 52.57 73 39.15 Triplex ADCOTE/ Sample BOPE Sample 1 1/ADCOTE/ PE Sealant Film Inventive MDO Sample 1/ 48 52.8 63 44.36 Triplex MOR-FREE/ Sample BOPE Sample 2 1/MOR-FREE/ PE Sealant Film Comparative BOPP* (20 μm 108 32.38 31 65.02 Triplex thickness)/ Sample ADCOTE/ 1 BOPE Sample 1/ADCOTE/ PE Sealant Film Comparative BOPET** (12 98 78.09 83 62.81 Triplex μm thickness)/ Sample ADCOTE/ 2 BOPA*** (15 μm thickness)/ ADCOTE/PE Sealant Film *BOPP is Biaxially Oriented Polypropylene **BOPET is Biaxially Oriented Polyethylene Terephthalate ***BOPA is Biaxially Oriented Polyamide

As shown above in Table 8, the Inventive Triplex Laminates 1 and 2 were isotropic, which is this case means that the percent elongation at break in the machine and cross directions deviated by less than 30%. The Inventive Triplex Laminates 1 and 2 outperforms Comparative Triplex Sample 1, which includes BOPP instead of BOPE, since Comparative Triplex Sample 1 has a percent elongation at break of 108% in the machine direction and 31% in the cross direction. Thus, Comparative Triplex Sample 1 was clearly not an isotropic film. Moreover, Inventive Triplex Laminates 1 and 2 performs comparably from an isotropic standpoint to Comparative Triplex Sample 2, which includes BOPET and BOPA instead of only polyethylene materials; however, Inventive Triplex Laminates 1 and 2 achieved that desired isotropic performance with a more easily recyclable polyethylene monomaterial laminate.

Referring to Table 10 below, the Inventive Triplex Laminates 1 and 2 were compared against the Comparative Triplex Samples 1 and 2 as well as Comparative Triplex Samples 3 and 4 in Table 9.

TABLE 9 Comparative BOPET** (12 μm thickness)/ADCOTE/BOPE Sample 1/ Triplex 3 ADCOTE/PE Sealant Film Comparative BOPET** (12 μm thickness)/ADCOTE/BOPP* (20 μm Triplex 4 thickness)/ADCOTE/PE Sealant Film

TABLE 10 Heat Seal Strength Comparative Comparative Comparative Comparative Inventive Inventive Temp. Triplex 1 Triplex 2 Triplex 3 Triplex 4 Triplex 1 Triplex 2 (° C.) (N/15 mm) (N/15 mm) (N/15 mm) (N/25 m) (N/25 m) (N/25 m) 90 0 0 0 0 0 0 100 2.936 4.584 4.53 5.47 4.812 5.946 105 16.234 19.94 19.586 12.386 17.138 16.162 110 28.164 57.12 30.104 32.418 21.712 39.616 115 38.862 67.28 32.484 39.438 24.346 43.636 120 32.234 54.854 35.336 44.86 30.87 51.132 130 36.698 68.75 32.896 47.45 35.218 51.6 140 48.392 67.41 38.864 43.544 37.68 53.606 150 52.65 73.554 43.07 47.186 44.342 55.552 160 56.532 70.246 42.256 50.484 44.982 50.716

For the heat sealing of the triplex laminates, it is desirable to have at least a 30 N heat seal strength throughout the sealing temperature window of 120-150° C. As shown in Table 10, the Inventive Triplex Laminates 1 and 2 met this requirement and thus performed comparably to the conventional Comparative Triplex Laminates 1-4; however, all of the Comparatives were not monomaterial polyethylene laminates like the Inventive Laminates and thus cannot achieve the desired recyclability. Only the monomaterial Inventive Triplex Laminates can achieve the desired heat seal strength, while also providing recyclability benefits.

It will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects. 

The invention claimed is:
 1. A laminate comprising: a uniaxially oriented first multilayer film comprising ethylene-based polymer having a density from 0.930 to 0.970 g/cm³ and a melt index (I₂) from 0.1 to 10 g/10 minutes, wherein the uniaxially oriented first multilayer film is oriented in the machine direction at a draw ratio greater than 3:1 and less than 8:1, and wherein the uniaxially oriented first multilayer film has a ratio of percent elongation at break in the cross direction to percent elongation at break in the machine direction of at least 2 to 1; a biaxially oriented second multilayer film adhered to the uniaxially oriented first multilayer film and comprising an ethylene-based polymer having a density from 0.900 to 0.962 g/cm³, wherein the biaxially oriented second multilayer film has a cross directional draw ratio larger than its machine direction draw ratio, and wherein the biaxially oriented second multilayer film has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction of at least 2 to 1; and a third multilayer film adhered to the biaxially oriented second multilayer film such that the biaxially oriented second multilayer film is disposed between the uniaxially oriented first multilayer film and the third film, wherein the third film comprising an ethylene-based polymer having a density from 0.865 g/cm³ to 0.935 g/cm³ and a melt index (I₂) from 0.5 to 5 g/10 minutes.
 2. The laminate of claim 1, wherein the third film has a Heat Seal Initiation temperature below 100° C.
 3. The laminate of claim 1, wherein the uniaxially oriented first multilayer film has percent elongation at break in the cross direction greater by at least 100% than percent elongation at break in the machine direction, and wherein the biaxially oriented second multilayer film has percent elongation at break in the machine direction greater by at least 100% than percent elongation at break in the cross direction.
 4. The laminate of claim 1, wherein the ratio of percent elongation at break in the cross direction to percent elongation at break in the machine direction of at least 3 to 1 for the uniaxially oriented first multilayer film, and has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction of at least 3 to 1 for the biaxially oriented second multilayer film.
 5. The laminate of claim 1, wherein the uniaxially oriented first multilayer film has a thickness from 15 to 30 μm, the biaxially oriented second multilayer film has a thickness of 15 to 100 μm, and the third film has a layer thickness from 40 to 100 μm.
 6. The laminate of claim 1, wherein the uniaxially oriented first multilayer film comprises: at least one outer layer having a high density polyethylene comprising a density of at least 0.950 g/cc, and a melt index (I₂) from 0.3 to 5 g/10 mins; at least one inner layer comprising an ethylene-based polymer having a density less than 0.920 g/cc and a melt index from 0.5 to 5 g/10 mins; and at least one intermediate layer disposed between the at least one inner layer and the at least one outer layer, the intermediate layer comprising an ethylene based polymer having a density greater than 0.930 g/cc.
 7. The laminate of claim 6, wherein the at least one inner layer comprises a polyolefin plastomer having a density less than 0.900 g/cc and a melt index from 0.5 to 5 g/10 mins.
 8. The laminate of claim 1, wherein the uniaxially oriented first multilayer film comprises at least 10% by weight HDPE.
 9. The laminate of claim 1, wherein the ethylene-based polymer of the biaxially oriented second multilayer film has a density of 0.915 to 0.940 g/cc, and a melt index from 0.5 to 2.0 g/10 mins.
 10. The laminate of claim 1, wherein the third film is a multilayer film, the multilayer film having a plurality of layers comprising ethylene based polymer.
 11. The laminate of claim 1, wherein the third film comprises a linear low density polyethylene having a density from 0.900 to 0.930 g/cc and a melt index (I₂) from 0.5 to 5.0 g/10 mins.
 12. The laminate of claim 1, wherein the third film comprises a low density polyethylene having a density from 0.915 to 0.935 g/cc and a melt index (I₂) from 0.3 to 3.0 g/10 mins.
 13. The laminate of claim 1, wherein the laminate comprises adhesive layers comprising polyurethane adhesive.
 14. The laminate of claim 1, wherein the laminate has a ratio of percent elongation at break in the machine direction to percent elongation at break in the cross direction from 1.3:1 to 1:1.3. 